Method and apparatus for punching terminal loops from multiple wire cable

ABSTRACT

The method and apparatus for punching terminal loops from multiple wire flat ribbon cable in which the wires are pulled bodily relative to their own loose insulation as the loops are formed to avoid wire drawing and reduction in cross section of the wire. The loops extend at right angles to the plane of the cable and are longitudinally and transversely spaced in groups in a staggered pattern. The loops are started adjacent the middle of the cable and are progressively formed toward each end, with immediately preceding loops forming anchoring points holding the wires, while new groups of loops are being pressed out toward the opposite ends. The wires are bodily slid within their insulating jackets from the ends to provide material for the newly formed loops. Punches and dies are mounted on slides movable in opposite directions from the center of the machine and cable and the slides are indexed in positions for punching a new group of loops and for anchoring an immediately preceding formed group by properly spaced lights which are indexed with a photocells on a slide. The cycle of operations repeats through the final groups of loops adjacent the ends of the cable whereupon the slides are returned to their central position and the cable is withdrawn, its ends sheared, and a new cable blank inserted into punching position.

United States Patent Webster I METHOD AND APPARATUS FOR PUNCHINGTERMINAL LOOPS FROM MULTIPLE WIRE CABLE [72]- lnventor: Adrian D.Webster, Huntington Beach,

Calif.

[73] Assignee: Spectra-Strip Corporation, Garden Grove,

Calif.

[22] Filed: Dec. 3, 1969 21 App1.No.: 881,730

Primary ExaminerLowell A. Larson Attorneyl. Morley Drucker 51 Jan. 25,1972 [57] ABSTRACT The method and apparatus for punching terminal loopsfrom multiple wire flat ribbon cable in which the wires are pulledbodily relative to their own loose insulation as the loops are formedtoavoid wire drawing and reduction in cross section of the wire. The loopsextend at right angles to the plane of the cable and are longitudinallyand transversely spaced in groups in a staggered pattern. The loops arestarted adjacent the middle of the cable and are progressively formedtoward each end, with immediately preceding loops forming anchoringpoints holding the wires, while new groups of loops are being pressedout toward the opposite ends. The wires are bodily slid within theirinsulating jackets from the ends to provide material for the newlyformed loops. Punches and dies are mounted on slides movable in oppositedirections from the center of the machine and cable and the slides areindexed in positions for punching a new group of loops and for anchoringan immediately preceding formed group by properly spaced lights whichare indexed with a photocells on a slide. The cycle of operationsrepeats through the final groups of loops adjacent the ends of the cablewhereupon the slides are returned to their central position and thecable is withdrawn, its ends sheared, and a new cable blank insertedinto punching position.

19 Claims, 20 Drawing Figures PATENTED JAN25 i972 SHEU 1 (IF 8 INVENTOR4004M M4=5575 BY a Z g mmmm I 4 1 mm m PATENIED M25872 SHEET 3 OF 8mam-1 LQNN mNN INVENTOR.

PATENTEU m2 51972 SHEET l 0F 8 40674 D, Wiasrfe @M 6% M24 METHOD ANDAPPARATUS FOR PUNCIIING TERMINAL LOOPS FROM MULTIPLE WIRE CABLECROSS-REFERENCE TO RELATED APPLICATION The method and apparatus of thisinvention form the conductor disclosed and claimed in the copendingapplication of Donald D. Lang, Ser. No. 859,258, filed Sept. 19, 1969,having a common assignee herewith, and the method defined herein is afurther development of the method disclosed and claimed in saidapplication.

BACKGROUND OF THE INVENTION 1. This invention relates to a method andapparatus for forming terminal loops in multiple wire cables used, forexample, in switching equipment of automatic telephone systems and thelike.

2. Multiple wire cables with spaced terminals of different form thanthat disclosed herein are known in the patents to McBerty, U.S. Pat. No.1,054,784, and Deakin, U.S. Pat. No. 2,433,346. The McBerty patent showsa woven multiconductor ribbon in which the weaving is interrupted atstaggered points to expose bare portions of the wire as terminals. TheDeakin patent shows a multiple wire, flat cable having loops in thewires which are bent to extend to the ribbon edge. Both the products andthe method of forming are distinct from those disclosed and claimedherein. Likewise, neither patent shows anything resembling the apparatusdisclosed and claimed in this application.

The copending application of Donald D. Lang, above identified, disclosesthe product formed by the method and apparatus in this application andalso a broad method of forming it which could be performed either bymachine or manually, and with the use of the simple tools described inthat application.

The present application discloses and claims an improved method andapparatus for efi'ecting formation of staggered terminal loops in amultiple wire cable starting from its midpoint and pulling the wires formaterial for the loops bodily in their insulating jackets from each endof the cable to form the loops without wire drawing and reduction incross section of the wire.

SUMMARY OF THE INVENTION As disclosed in the above-identified copendingapplication of Donald D. Lang, the individual wires of the cable haveloose-fitting insulating jackets of, for example, polyvinyl chloride,and the flat ribbon cable may be formed by bonding together theinsulating jackets of a plurality of parallel wires into a flat ribbonconfiguration in the manner, for example, disclosed and claimed in U.S.Pat. No. 3,005,739, granted Oct. 24, I96 l for METHOD AND APPARATUS FORMAK- ING MULTICONDUCTOR CABLE. The wires of the cable have terminalloops pressed therefrom at right angles to their insulation by anexternal punch operating from the side opposite the formed loop. Thewires are pulled bodily down the center of their own insulation from anend of the cable so that loops are formed without wire drawing andreduction in cross section.

To insure that the wires are slid from the same end of the cable as theloops are consecutively formed, each formed loop becomes an anchor pointwhile the next succeeding loop is being formed, thereby insuring thatthe wires are pulled bodily from the end of the cable toward which theloops are progressing. The previously formed loops in the groups areanchored by engaging them with punches and dies similar to the punchesand dies which form the loops and spaced therefrom a fixed distancecorresponding to the spacing along the wires of the terminal loops.

The loops are first punched at the middle of the cable by first punchinga pair of immediately adjacent groups of loops at the center andthereafter punching the next groups of loops toward the opposite ends.The punches and dies are mounted in paired sets movable independentlytoward the opposite ends of the cable in steps corresponding to thespacing between the groups so that the inward sets of punches and diesenter the terminal loops formed by the outer sets of punches and dies toanchor the same in position while the outer sets thereafter punch thenext group of terminal loops toward the ends of the cables, therebypulling the wires from the cable ends to provide the material for theloops without wire drawing. The operation of the inner and outer punchesis timed so that the inner punches engage in the immediately previouslyformed loops before a new group of loops is formed by the outer set ofpunches and dies.

The sets of punches and dies are indexed in position by properly spacedlights on the machine which cooperate with a photocell movable with aset of punches and the operation proceeds automatically, once started,until the end of the cable is reached, whereupon the sets of punches anddies, now at the opposite ends of the cable, are automatically returnedto the central position ready to start at the center of a new cableblank in which loops are to be formed.

The cables are mounted on a supporting frame and a completed cable iswithdrawn from the machine and positioned for automatic trimming of theexcess insulating jacket material from its ends. The frame hasprovisions for supporting a new cable blank while a cable is havingterminal loops formed therein and, after shearing of the formed cable,the frame is manipulated to insert the new cable blank into the machine,whereupon the loop forming operation may be started thereon.

Punching movements of the sets of punches and dies is controlled by theapplication of pneumatic pressure to operating cylinders, and thesequence of operation of the inner and outer sets of punches iscontrolled by flow control valves. The sets of punches and dies aremounted in oppositely moving pairs in side-by-side relation on slideswhich are moved by an oppositely threaded, rotating screw operated byclutch and brake control from an operating motor.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a front elevational view ofthe apparatus according to the present invention;

FIG. 2 is a plan view of the apparatus of FIG. 1 in a differentposition;

FIG. 3 is a detail view of an operating switch on the line 3- 3 of FIG.2;

FIG. 4 is an enlarged vertical sectional view on the line 4-4 of FIG. 1;

FIG. 4a is a detail view on the line 4a4a of FIG. 4;

FIG. 5 is a view similar to FIG. 4 with the parts in differentpositions;

FIG. 6 is a vertical sectional view on the line 66 of FIG. 2;

FIG. 7 is a diagrammatic representation of the cable carrier frame interminal loop punching position;

FIG. 8 is a view similar to FIG. 7 but with the cable carrier frameretracted;

FIG. 9 is a view similar to FIGS. 7 and 8 with the carrier frame incable-trimming position;

FIG. I0 is a view showing a paired set of loop-forming punches taken onthe line 10-10 of FIG. 6;

FIG. 11 is a vertical sectional view through a punch and die taken onthe line l1l1 of FIG. 10;

FIG. 12 is an enlarged view of a punch pressing a terminal loop in acable wire;

FIG. 13 is an expanded view of the plates of a die;

FIG. 14 is a detailed view of a die plate showing the openings therein;

FIG. 15 is a sectional view through a punch taken on line FIG. 19 is apneumatic diagram for the machine.

DETAILED DESCRIPTION The apparatus of the present invention and by whichthe method of the invention may be carried out is mounted on aninverted, U-shaped base channel 21. A pair of end supporting plates 22and 23 and a central supporting plate 24 are mounted on the uppersurface of the base channel by welding, bolting or other means to berigid therewith. Rigidly mounted in the plates 22-24 and extendinglongitudinally of the machine are parallel rods 25 and 26 on which areslidably mounted blocks 27 and 28 mounted, respectively, between theplates 22 and 24, and 23 and 24.

Rotatably mounted in the plates 22-24 is a lead screw 29 havingoppositely threaded half portions 31 and 32 on opposite sides of thecentral plate 24. Rigidly secured to and depending from the blocks 27,28 are supporting plates 33 and 34. Upon the plates 33, 34 are mountedthreaded blocks 35, 36 into which the screw halves 31 and 32 arethreaded so that the blocks 35, 36 act as travelling nuts on the screw29, movable in opposite directions as the screw is rotated to move theblocks 27, 28 therewith in opposite directions. The screw 29 has apulley 37 on its end connected by a link belt or the like 38 to a pulley39 on the output side ofa clutch and brake control 41 which is coupledat 42 to an electric motor 43.

Rigidly mounted on the top of the slide block 27 are a pair of pivotposts 44 and 45 on which are pivotally mounted lever arms 46 and 47intermediate their ends. Rigidly mounted on the top ofthe slide block 28are a pair of pivot posts 48 and 49 on which are pivoted a pair of leverarms 51 and 52 intermediate their ends. At the back of the slide block27 are mounted supporting brackets 53, 54 and at the back of the slideblock 28 are mounted supporting brackets 55 and 56. On the brackets53-56 are mounted four pneumatic operators 57, duplicating the one shownin FIG. 4 on the bracket 55. The pneumatic operators 57 have extendingupwardly therefrom piston connected actuators 58, 59, 60 and 61,pivotally connected to the rear ends of the levers 46, 47, 51 and 52. Oneach of the actuators 58-61 are rigidly secured plates 62 on which aremounted stop rods 63 carrying stop nuts 64 and 64a cooperating with thebrackets 53-56; 64 limiting the upward movement and 64a the downwardmovement of the actuators 58-61, as shown more particularly in FIG. 4.

On the forward ends of the lever arms 46, 47, 51 and 52 are pivotallymounted punch-operating rods 65, 66, 67 and 68, respectively, to thelower ends of which are pinned punch plates 69, 70, 71 and 72. The punchplates are slidably mounted for vertical movement on guide posts 73rigidly mounted in and depending from the slide blocks 27 and 28.Rigidly mounted on and depending from the punch plates 69-72 are punchblocks 74 carrying rigid punches 75 and resiliently mounted stripperplates 76. This structure is shown in FIG. 4 and is duplicated for eachofthe punch plates 69-72.

At the bottom of each of the supporting plates 33, 34 is pivotallymounted a die carrier 77, 78. Each of the die carries 77, 78 carries apair ofdies 79 thereon, each located beneath a punch block 74, in themanner shown in FIG. 4. Pivotal downward movement of the dies 79 islimited by stops 81 carried on the blocks 35, 36. The die carriers 77,78 are held in their upward position, as shown in FIG. 4, by means ofeccentrics 82, 83, 84 carried on a shaft 85 journaled in the end plates22 and 23 and in intermediate blocks 86 and 87 mounted on the top of thebase channel 21, as shown in FIGS. 1 and 4. The shaft 85 has an arm 88rigidly extending therefrom to which is pivotally connected the actuator89 ofa pneumatic operator 91, pivoted at 92 in a bracket rigidly mountedon the base channel 21. As the actuator 89 is extended and retracted, itrotates the shaft 85 and therewith the eccentrics 82-84 to move the diecarriers 77, 78 between the upper position of FIG. 4 and the lowerposition of FIG. 5. The cavities ofthe die 79 are in communication withan air passage 93 fed by pneumatic tubing 94, as will be hereinafterexplained.

Rigidly secured to and depending from the supporting plate 33 is abracket 95 which carries a photoelectric cell 96 and an electric switch97. Rigidly secured between the plates 22 and 24 is a supporting rod 98on which are mounted, in spaced relation, a plurality of light blocks 99shown in detail in FIGS. 4 and 4a. The light blocks 99 are adjustablyspaced on the rod 98 by means of nuts 101 and have openings 102 in linewith the path of movement of the photoelectric cell 96 in which areplaced light bulbs 103. The front ofthe blocks 99 are provided withadjustable light shading plates whose edge 105 determines the point atwhich the light from the bulb 103 actuates the photoelectric cell 96 toeffect conduction thereof. The light blocks 99 and lights 103 are spacedlongitudinally of the rod 98 the distance between the terminal loops inadjacent groups in the cable and control movements of the slide blocks27 and 28 to the spacing between groups, as will be explainedhereinafter. The light blocks 99 have operating projections 106 thereonfor actuating the switch 97 for a purpose to be explained.

Mounted on the base channel 21 are a pair of longitudinally spaced,vertical, forwardly extending, supporting plates 107 and 108 having inopposed faces horizontal supporting slots 109 communicating withvertical slots 111. Within the supporting slots 109 ride forward rollers112 and rear rollers 113, supporting a rectangular frame 114 designed tocarry the wire cable. For this purpose the frame 114 carries on forwardand rear opposite corners longitudinally extending brackets 115 and 116each carrying a pair oflongitudinally extending spring arms 117 and 118between which is clamped the multiple wire, flat ribbon cable 119. Thespring arms 117 and 118 are provided with groups of spaced holes offsetin staggered rela tion at 121 in FIG. 2 through which the punches 75extend in pressing out the terminal loops from the wires.

The vertical slots 111 are normally closed by slides 122, which howeverhave openings 123 adapted to be aligned with the slots 111 to permitpassage of the wheels 112 or 113 therethrough. The slides 122 haveinwardly projecting forward pins 124 and rearward pins 125 thereonextending through slots 126 in the supporting plates 107 and 108. Thecable carrying frame 114 has pins 127 and 128 projecting oppositelytherefrom in positions to engage the pins 124 and 125 on the slides 122.Immediately above the vertical slots 111 the supporting plates 107 and108 carry switch operators 129 adapted to operate switches 131 and 132.The operation of the frame 114 is illustrated in FIGS. 7-9 and will beexplained more fully hereinafter.

Means are provided for trimming the excess insulation from the ends ofthe completed cable, shown more particularly in FIGS. 1,4 and 16. Thecutting lines are shown at 133 and 134 in FIG. 4 as determined by thestationary cutting blades 135 and movable cutting blades 136. Thestationary cutting blades 135 are mounted on blocks 137 supported onvertical plates 138 suspended from the base channel toward each endthereof in the positions shown in FIG. 1. The movable blades 136 aremounted on hinged arms 139 pivotally connected to actuators 141 ofpneumatic operators 142. Energization of the pneumatic operators 142 iscontrolled by the switches 131 and 132, as will be explainedhereinafter.

FIG. 10 shows a pair of punch blocks 74 as they are mounted togetherfrom the punch plates 69-72 under a slide block 27 or 28. The positionof the cable 119 is dotted in and the punches 75 as spaced along thecable 119 and transversely thereofin staggered relation. The stripperplate 76 is shown in FIG. 11 as mounted on movable posts 143 in thepunch block 74 and biased downwardly by compression springs 144. FIG. 11also shows on an enlarged scale the cooperation between the punches 75and the dies 79 with the cable 119 therebetween.

The operation of the punches 75 cooperating with the die openings isshown in FIG. 12 where the punch end 145 has passed through the cableinsulation 146 to engage a wire 147 and form a loop 148 therein withinthe die cavity 149.

The die is shown in FIGS. 11 and 13 to be made up ofa plurality ofplates 151 having die openings 149 therein which are spacedlongitudinally in adjacent plates so that when assembled in the positionofFlG. 11, the die openings 149 assume a staggered relationcorresponding to the staggered relation of the punches 75 in FIG. 10.The plates 151 have openings 152 therethrough communicating with the dieopenings 149 and overlapping with the openings of adjacent plates, as at153, so as to permit the air entering through passage 93 to pass fromplate to plate and from opening 149 to opening 149 whereby air enteringthe manifold chamber 154 from passage 93 will pass successively throughthe die openings 149 and serve to blow out pieces of insulation whichmay be cut from the cable from the die openings.

FIG. 17 illustrates a portion ofa finished cable 119 in which terminalloops 148 have been punched in staggered relation in groups spacedlongitudinally of the cable.

Switches 161, 162 and 163 shown on the apparatus and on the wiringdiagram of FIG. 18 are manually operated switches. A machine-operatedswitch is shown in FIG. 3 at 164 operated by a pair of arms 165 and 166rigidly mounted on the pivoted arm 46 to be moved therewith to actuatethe switch 164 respectively to off" and on positions. Othermachineoperated switches are shown on the apparatus and in FIG. 18 at165-169. Also included in the wiring diagram of FIG. 18, are a relay 160with normally open and closed contacts, a relay 170 with a double-throwcontact for the clutch and brake control, a motor-reversing relay 171, arelay 172 with a normally open contact, a time-delay relay 173 with anormally open contact, a relay 174 with normally open and normallyclosed contacts, a relay 175 having a normally open contact controllinga solenoid-valve operating coil 176, a relay 177 having a normally opencontact, a relay 178 having a normally closed and two normally opencontacts, a relay 179 having normally open and normally closed contacts,a relay 180 having a normally closed contact, and a time-delay relay 181having a normally open contact controlling a second solenoidvalveoperating coil 182.

The pneumatic diagram shown in FIG. 19 comprises an air pressure source183 regulated to a predetermined value by regulator 184, and feeding totwo solenoid valves, one at 185 having the operating coil 176, and theother at 186 having the operating coil 182. The valve 185 controls theflow of air pressure to the opposite ends of the cylinders of operators57 and 91, while the valve 186 controls the application of fluidpressure to the single end of the cutter operators 142, these beingreturned to unactuated position by return springs 187.

The operators 57 are provided with flow control adjustable valves 188,189, 190 and 191, which control the return rate of flow from above thepistons of the operators, and therefore control the speed of downwardmovement of the punches which they operate. The flow control valves188-191 are bypassed by check valves 192 to permit rapid flow of airpressure entering above the pistons of the operators 57. The air beneaththe pistons of the operators 57 is exhausted through the die blow outpassages 93.

The flow control valves 188-191 are first adjusted so that the operator91 will move the eccentrics 82-84 to their upward position supportingthe dies before the punches engage the cable. The flow control valvesare then adjusted so that the inner lever arms 47 and 51 will be firstmoved by their operators 57 to move their punches 75 into the dieopenings 149 before the punches operated by the outer lever arms 46 and52 are engaged with the wires of the cable to press loops 148 therefrom.Thus, the sequence of operation is to first operate 91 to raise the diesinto upper position, then lower the punch plates 70 and 71 and thepunches mounted thereon, and finally lower punch plates 69 and 72 andthe punches mounted thereon. This method of operation, according to thepresent invention, is desired so as to always pull the wires withintheir insulating jackets from an end of the cable. Thus, in the initialpunching operation, the punch plates 70 and 71 are moved downwardly topress out the groups of loops 148 immediately adjacent the center of thecable 119. In so pressing out the loops, the wires 147 are pulledlongitudinally Within their insulating jackets from the opposite ends ofthe cable. Subsequent to this operation, the punch plates 69 and 72 aremoved downwardly to form the next groups of terminal loops 148 towardthe opposite ends of the cable, again pulling the wires 147 throughtheir insulating jackets 146 from the opposite ends of the cable. Thenext operation raises all the punch plates and lowers all the dies, andmoves them on their slide blocks 27 and 28 one step toward the oppositeends of the cable, thereby moving the punches on the punch plates 70, 71into indexing relation with the last formed group of terminal loops.Thereafter, the dies are raised into position and the punch plates 70and 71 move downwardly to lock in the last formed terminal loops andthereafter the punch plates 69 and 72 are lowered to press out newgroups of terminal loops toward the opposite ends of the cables, againpulling the wires 147 only from the opposite ends of the cable. Theprocess continues step by step to the end of the cable, whereuponlongitudinal movement of the punches and dies is reversed, and they arereturned to the center of the machine to operate on a new cable blank.The formed cable is now withdrawn from the punching position by pullingthe frame 114 to the rear; the formed cable is trimmed and a new cableis inserted into punching position, as will be explained in the machineoperation sequence.

In operation, the flow control valves 188-191 are first adjusted tosecure the desired sequence of operation, that is, upon energization ofthe solenoid 176 of valve 185 to first completely move the operator 91,then completely move the punch plates 70 and 71 downwardly by the twoinner operators 57 and thereafter completely move the punch plates 69and 72 downwardly by the outside operators 57.

The apparatus is turned on by closing switch 163 which energizes themotor 43 and the clutch brake control 41 from the direct current sourcetherefor, shown as a battery in FIG. 18. Switch 162 is closed to placepower from the supply line 195 to the pushbutton switch 161, and also online 196 to the circuit for valve-operating solenoid 182. The othersupply line is designated 197 and a control line is designated 198.Unless previously loaded on the frame 114, a cable blank 119 of a lengthgreater than the desired finished product by the amount the wires are tobe pulled within their insulation to form the loops 148 is loadedbetween the spring plates 117 and 118, as shown in FIG. 5, and then theframe moved forwardly into the punch position shown in dotted linestherein. At this time, the die carrier will be lowered and the punchblock raised, also as shown in FIG. 5. With the frame 114 in forwardposition, safety switches 168 and 169 will be closed.

The start switch 161 is now closed momentarily, thereby energizing theoperating coil of relay 172 through the switches 168 and 169, whereuponits normally open contact closes to place a holding circuit around themomentary switch 161, and thereby energizing control line 198. Thisenergizes the light transformer through the normally closed contact ofrelay 179 so that lights 103 are illuminated. The coil of time delayrelay 173 is energized and, after its time setting of, for example, 2seconds duration, it closes its contact and energizes the circuit of thephotoelectric cell 96. Due to the fact that the lamps 103 are alreadyilluminated, as soon as the photoelectric cell circuit is energized,relay operates to open its contact, thereby preventing energization ofrelay 174, whereby the brake unit of the clutch and brake control 41remains energized. The screw 29 does not rotate and the slide blocks 27and 28 remain stationary.

When the contact of relay 173 closes, relay 175 is energized to closeits contact and energize the solenoid 176 of valve 185. Valve nowapplies air pressure beneath the pistons of the operators 5 7 and to theright-hand side of the operator 9]. According to the sequencing setup ofthe valves 188-191, the operator 91 moves immediately to move theeccentrics 82-84 upwardly and therewith the die supports 78 and the dies79 thereon. The pistons of the operators 57 also start to move upwardlybut with the inner two operators 57 moving faster so that the punchplates 70 and 71 and the punches thereon come down first to press outthe groups of terminal loops 148 immediately adjacent the center of thecable 119. The two outer operators 57 operate after the two inneroperators to lower the punch plates 69 and 72 and the punches thereon toform outside groups of loops 140. In each instance, the wires 147 aredrawn bodily longitudinally of the insulating jackets 146 to form theloops 148 without wire drawing and without reduction in cross section ofthe wires.

When the operating arms 165 opens switch 164 as the lever arms 46 movesupwardly, thereby deenergizing the solenoid 176, the valve 185 reversesposition under its spring bias to apply pressure to the top of theoperators 57 and to the lefthand side of the operator 91 to retract theactuators 58-61 of the operators 57 and to extend the actuator 89 of theoperator 91. This moves the punches to their upper position of FIG. 5,and moves the die holders to their lower position in the same figure,thereby releasing both the punches and the dies from the formed loops148.

As the lever arm 46 rotates back, adjacent the end of its stroke itrecloses switch 164 and closes switch 165. Switch 165 energizes relay179, thus opening its normally closed contacts and deenergizing the lamptransformer to extinguish the lamps 103. This in turn deencrgizesphotoelectric cell 96 to deenergize relay 180 whose normally closedcontact now closes to energize the operating coil of relay 174, whichoperates to energize relay 177 whose normally open contact closes toenergize relay 170, thereby releasing the brake and engaging the clutchof control 41 so that the screw 29 rotates to move the slide blocks 27and 28 toward the opposite ends of the machine. As the side blocks moveout, switch 97 is operated by the projection 106 on the adjacent lightblock 99 and cuts off the energization of relay 179, whereby the lighttransformer is reenergized to illuminate the lights 103. The screw 29continues to rotate and the slides 27 and 28 move outwardly until thephotoelectric cell 96 comes in alignment with the next light 103 which,as stated, is located at a distance to align the inner sets of puncheswith the groups of terminal loops previously formed by the outer sets ofpunches.

When photoelectric cell 96 is illuminated, relay 180 is energized toopen its contact and deenergize relay 174 which, in reverse sequence,deenergizes relay 170 to reenergize the brake and deenergize the clutchof control 41 whereupon the slides 27, 28 come to rest. Relay 175 isagain energized, solenoid 176 of valve 185 is reenergized, and airpressure is again applied to the lower end of the operators 57 and tothe righthand end ofthe operator 91.

The cycle of operation repeats with the die holders 77, 78 being firstraised and then the punch plates 70, 71 lowered to lock the last formedgroups of loops 148 in the innermost dies and punches. The outermostpunches subsequently lower with punch plates 69 and 72 to form newgroups ofloops 140, and switch 164 is again operated to deenergize thesolenoid 176 whereupon the valve 185 operates to return the punches anddies to their open positions. At-the end of the stroke switch 164 isagain closed, as is switch 165, to again start rotation of the screw 29and movement ofthe slide blocks 27 and 28 outwardly.

This cycle of operation is repeated up to the formation of the finalgroups of terminal loops 148 adjacent the ends of the cable 119, andthen instead of switch 97 being operated, the slide blocks continue onuntil switch 166 is operated, energi2 ing relay 178 to keep the brakeofthe control unit 41 deenergized and, at the same time, energizing themotor reversing relay 171 which, since the lamps are no longer on,affects return movement of the slide blocks 27 and to the middle of themachine. Just before the photoelectric cell 96 gets to the most centrallamp 103, switch 167 is operated to put the lamps 103 back on so thatwhen the photoelectric cell 96 reaches this last lamp, the slide blocks27 and 28 are brought to a stop in the middle of the machine, as shownin FIG. 1. When switch 167 was operated, it energized relay 160 whichopens the circuit to the energizing coil of relay 175 to preventsolenoid 176 of valve 105 from being energized.

While the cable in punching position was having the terminal loops 148pressed therefrom, preferably a new cable blank was inserted between theresilient plates 117, 118 at the back of the frame, that is, at the leftas viewed in FIG. 4. With punching of the cable completed, the frame 114is pulled rearwardly to the full-line position of FIG. 5, correspondingto the diagrammatic representations of FIG. 7. In this movement, theroller 113 moves past the vertical slot 111 which is closed off by theslide 122. However, toward the extreme rear movement of the frame 114,the pins 128 engage the pins on the slide 122 and move it rearwardly aswell, to index the opening 123 with the slot 111. Therefore, when theroller 112 is placed above the slot 111, as in FIG. 5 and FIG. 8, theroller 112 moves downwardly through the opening 123 and the slot 111,and the roller 113 moves forwardly until the frame 114 assumes avertical position, as shown in FIG. 9. At this time, the rollers 113engage the switch operators 129 to close the switches 131, 132. Thisenergizes the operating coil of the time delay relay 181, which afterits predetermined time setting of, for example, 5 seconds, closes itscontact to energize the solenoid 132 of valve 186. Valve 186 istherefore operated to introduce air pressure to the operators 142, whichthereupon extend their actuators 141 to move the cutting blades 136against the stationary cutting blades 135, thereby trimming the excessinsulation from the ends of the formed cable 119. After the trimmingoperation, the rollers 113 on frame 114 are moved forwardly in the slots109 and the rollers 112 move vertically upward in the slots 111 untilthey enter the horizontal slots 109, whereupon the frame 114 is pushedforwardly into punching position with the new cable blank in position tohave terminal loops punched or pressed therefrom. In the extreme forwardmovement of the frame, the pins 127 engage the pins 125 to move theslides 122 forwardly to bring the opening 123 out of alignment with thevertical slot 111 to therefore prevent the now rearward rollers 112 fromdropping into the vertical slots 111.

When the frame 114 moved rearwardly from the punching position, thesafety switches 168 and 169 opened to deenergize the entire electricalsystem except for the cable trimming circuit. When the frame isreinserted into punching position, reversed top for bottom as previouslydescribed, switches 168 and 169 are again closed preparatory to startinga new terminal loop punching process when the pushbutton switch 161 isagain momentarily depressed.

While a certain preferred method and apparatus according to the presentinvention have been specifically illustrated and described, it will beunderstood that the invention is not limited thereto as many variationswill be apparent to those skilled in the art.

Iclaim:

1. The method of forming a plurality of base terminal loops spaced alongthe length of an insulated conductor which comprises:

providing a wire conductor with a loose-fitting insulating jacket withinwhich the wire is bodily movable;

punching two terminal loops from the wire out through its insulationadjacent the center of the conductor, the wire being pulled bodilywithin its insulation from opposite ends to supply material for theloops; punching two additional terminal loops in the same manner andspaced from the original loops towards the ends of the conductor whileanchoring the original two loops in punch position so as to pull thewire to form the new loops only from the opposite ends of the conductor;and

punching additional terminal loops in the same manner at spacedintervals along the length of the conductor while anchoring eachimmediately previously formed loop in punch position so as to pull wireto form the new loops only from the ends of the conductor.

2. The method of forming base terminal loops on a multiple wire flatribbon cable comprising:

providing a plurality of parallel wire conductors with loose fittinginsulating jackets within which the wires are bodily movable and whichare arranged as a flat ribbon cable;

punching two groups of terminal loops in the wires through theirinsulating jackets adjacent the center of the cable, the loops of eachgroup being in longitudinally and transversely spaced relation in astaggered pattern, and the wires being pulled bodily within theirjackets from opposite ends to supply material for the loops;

punching two additional groups of terminal loops in the same manner andspaced from the original two groups of loops toward the ends of thecable while anchoring the original two groups of loops in punch positionso as to pull the wires to form the new loops only from the oppositeends of the cable; and

punching additional groups of terminal loops in the same manner atspaced intervals along the length of the cable while anchoring eachimmediately previously formed group of loops in punch position so as topull wires to form the new loops only from the ends of the cable.

3. The method defined in claim 2 including:

cutting an original cable blank to the length greater than that of thedesired formed cable by at least the amount the wires are withdrawn fromtheir jackets; and

trimming the excess insulation from the ends of the formed cable.

4. The method defined in claim 2 including:

punching the additional groups of terminal loops along the length of thecable progressively from the center toward the opposite ends of thecable so that the newly formed groups of loops are always on the cableend sides of the immediately previously formed groups of loops.

5. The method defined in claim 2 including:

punching the terminal loops with dies on one side of the cable andgroups of staggered punches on the opposite side of the cable;

separating said dies and punches from the cable and terminal loops;

moving said dies and punches relative to the cable to a position toanchor the immediately previously formed groups of loops preparatory topunching new groups of loops; and

contacting said dies and groups of punches with the cable to form theanchoring and punching operations recited.

6. The method defined in claim 5 including:

positioning the dies relative to the cable before engaging the punchestherewith; and

engaging the punches with the immediately previously formed groups ofloops in anchoring relation before punching the new groups of loops fromthe cable wires.

7. The method defined in claim 6 including:

terminating the punching of additional groups of terminal loops adjacentthe opposite ends of the cable; and

returning said dies and punches to their positions adjacent the centerof the cable to operate upon a new cable blank.

8. The method defined in claim 7 including:

trimming the excess insulating material from the ends of the cable leftafter pulling the wires therefrom to form the material for the terminalloops.

9. Apparatus for forming base terminal loops on a multiple wire flatribbon cable comprising:

means for supporting a multiple wire flat ribbon cable in punchingposition;

first and second punch means disposed on one side of said cable;

means mounting said first and second punch means for punching movementtoward said cable to punch terminal loops therefrom and for bodilymovement in opposite directions from the center toward the ends of thecable;

third and fourth punch means mounted alongside said first and secondpunch means on the same side of the cable and movable both in punchingoperations and in simultaneous bodily movement, respectively, with saidfirst and second punch means;

die means on the opposite side of said cable cooperating with said punchmeans in the formation of terminal groups in the cable wires;

said die means being movable with the punch means longitudinally of thecable and being movable toward the cable to receive the punch means inthe loop-forming operation;

means for effecting movement of the die means toward the cable intoposition to receive the punch means;

and means for effecting movement of the punch means toward the cable inthe sequence of the first and second inner punch means in advance of theoperation of the third and fourth outer punch means.

10. The apparatus defined in claim 9 including:

means for moving said punch means together adjacent the center of acable blank,

means for first operating the first and second inner punch means topunch terminal loops in the cable wires adjacent the center of the cablewhile drawing wires for the loops from the ends of the cable; and

means for subsequently punching terminal loops by operation of the thirdand fourth punch means while said first and second punch means remain inpunching position to anchor the loops formed thereby whereby wire forthe loops punched by the third and fourth outer punch means is pulledfrom the ends of the cable.

11. The apparatus defined in claim 10 including:

means for moving the die means and punch means away from the cable afteroperation of the third and fourth punch means,

means for moving the first and third, and the second and fourth punchmeans and the die means cooperating therewith in opposite directionsfrom the center toward the ends of the cables,

means for stopping said punch means with the first and second punchmeans in alignment with the terminal loops formed by the third andfourth punch means,

means for thereafter moving the first and second punch means and the diemeans cooperating therewith into engagement with the terminal loopspreviously punched by the third and fourth punch means whereby to anchorsaid terminal loops, and

means for thereafter moving said third and fourth punch means to punchadditional terminal loops from the cable while pulling wires to form theloops from opposite ends of the cable.

12. The apparatus defined in claim 11 in which the means for stoppingsaid punch means with the first and second punch means in alignment withthe terminal loops punched by the third and fourth punch meanscomprises:

cooperating spaced lights and a photocell for stopping movement of thepunch means after a distance corresponding to the spacing between theterminal loops formed by the respective first and third, and second andfourth punch means.

13. The apparatus defined in claim 9 including:

said first and third punch means, and said second and fourth punch meansbeing mounted, respectively, on common carrier means, and

said die means cooperating with said punch means being also mounted onsaid common carrier means; and

means for simultaneously moving said carrier means in oppositedirections longitudinally of the cable.

14. The apparatus defined in claim 13 including:

piston-and-cylinder operating means for said punch means individualthereto and also mounted on the carrier means to be bodily movabletherewith.

15. The apparatus defined in claim 9 including:

supporting means for said die means extending longitudinally of thecable when in punch position, and movable into and out of positionsupporting the die means adjacent the cable for punching operation.

16. The apparatus defined in claim 9 including:

llll

means for operating supporting means for the die means in synchronismwith the operation of the punch means so that the die means is movedinto supported position to receive the punch means prior to operation ofany punch means into engagement therewithi B7. The apparatus defined inclaim 9 including air blast means cooperating with said die means forblowing insulating particles cut from the cable from the die apparatus.

18. The apparatus defined as in claim 9 including: a movable frame uponwhich said cable is mounted in supported relation; means supporting saidframe for movement into and out of cable punching position;

trimming means for the ends of the cable;

and means for swinging said frame while supported in the apparatus toposition the ends of the cable adjacent the trimming means for atrimming operation removing excess insulation from the ends of thecable.

19. The apparatus defined in claim 18 including:

means for automatically operating said trimming means after said framehas swung into the position locating the ends ofthe cable at thetrimming means.

1. The method of forming a plurality of base terminal loops spaced alongthe length of an insulated conductor which comprises: providing a wireconductor with a loose-fitting insulating jacket within which the wireis bodily movable; punching two terminal loops from the wire out throughits insulation adjacent the center of the conductor, the wire beingpulled bodily within its insulation from opposite ends to supplymaterial for the loops; punching two additional terminal loops in thesame manner and spaced from the original loops towards the ends of theconductor while anchoring the original two loops in punch position so asto pull the wire to form the new loops only from the opposite ends ofthe conductor; and punching additional terminal loops in the same mannerat spaced intervals along the length of the conductor while anchoringeach immediately previously formed loop in punch position so as to pullwire to form the new loops only from the ends of the conductor.
 2. Themethod of forming base terminal loops on a multiple wire flat ribboncable comprising: providing a plurality of parallel wire conductors withloose fitting insulating jackets within which the wires are bodilymovable and which are arranged as a flat ribbon cable; punching twogroups of terminal loops in the wires through their insulating jacketsadjacent the center of the cable, the loops of each group being inlongitudinally and transversely spaced relation in a staggered pattern,and the wires being pulled bodily within their jackets from oppositeends to supply material for the loops; punching two additional groups ofterminal loops in the same manner and spaced from the original twogroups of loops toward the ends of the cable while anchoring theoriginal two groups of loops in punch position so as to pull the wiresto form the new loops only from the opposite ends of the cable; andpunching additional groups of terminal loops in the same manner atspaced intervals along the length of the cable while anchoring eachimmediately previously formed group of loops in punch position so as topull wires to form the new loops only from the ends of the cable.
 3. Themethod defined in claim 2 including: cutting an original cable blank tothe length greater than that of the desired formed cable by at least theamount the wires are withdrawn from their jackets; and trimming theexcess insulation from the ends of the formed cable.
 4. The methoddefined in claim 2 including: punching the additional groups of terminalloops along the length of the cable progressively from the center towardthe opposite ends of the cable so that the newly formed groups of loopsare always on the cable end sides of the immediately previously formedgroups of loops.
 5. The method defined in claim 2 including: punchingthe terminal loops with dies on one side of the cable and groups ofstaggered punches on the opposite side of the cable; separating saiddies and punches from the cable and terminal loops; moving said dies andpunches relative to the cable to a position to anchor the immediatelypreviously formed groups of loops preparatory to punching new groups ofloops; and contacting said dies and groups of punches with the cable toform the anchoring and punching operations recited.
 6. The methoddefined in claim 5 including: positioning the dies relative to the cablebefore engaging the punches therewith; and engaging the punches with theimmediately previously formed groups of loops in anchoring relationbefore punching the new groups of loops from the cable wires.
 7. Themethod defined in claim 6 including: terminating the punching ofadditional groups of terminal loops adjacent the opposite ends of thecable; and returning said dies and punches to their positions adjacentthe center of the cable to operate upon a new cable blank.
 8. The methoddefined in claim 7 including: trimming the excess insulating materialfrom the ends of the cable left after pulling the wires therefrom toform the material for the terminal loops.
 9. Apparatus for forming baseterminal loops on a multiple wire flat ribbon cable comprising: meansfor supporting a multiple wire flat ribbon cable in punching position;first and second punch means disposed on one side of said cable; meansmounting said first and second punch means for punching movement towardsaid cable to punch terminal loops therefrom and for bodily movement inopposite directions from the center toward the ends of the cable; thirdand fourth punch means mounted alongside said first and second punchmeans on the same side of the cable and movable both in punchingoperations and in simultaneous bodily movement, respectively, with saidfirst and second punch means; die means on the opposite side of saidcable cooperating with said punch means in the formation of terminalgroups in the cable wires; said die means being movable with the punchmeans longitudinally of the cable and being movable toward the cable toreceive the punch means in the loop-forming operation; means foreffecting movement of the die means toward the cable into position toreceive the punch means; and means for effecting movement of the punchmeans toward the cable in the sequence of the first and second innerpunch means in advance of the operation of the third and fourth outerpunch means.
 10. The apparatus defined in claim 9 including: means formoving said punch means together adjacent the center of a cable blank,means for first operating the first and second inner punch means topunch terminal loops in the cable wires adjacent the center of the cablewhile drawing wires for the loops from the ends of the cable; and meansfor subsequently punching terminal loops by operation of the third andfourth punch means while said first and second punch means remain inpunching position to anchor the loops formed thereby whereby wire forthe loops punched by the third and fourth outer punch means is pulledfrom the ends of the cable.
 11. The apparatus defined in claim 10including: means for moving the die means and punch means away from thecable after operation of the third and fourth punch means, means formoving the first and third, and the second and fourth punch means andthe die means cooperating therewith in opposite directions from thecenter toward the ends of the cables, means for stopping said punchmeans with the first and second punch means in alignment with theterminal loops formed by the third and fourth punch means, means forthereafter moving the first and second punch means and the die meanscooperating therewith into engagement with the terminal loops previouslypunched by the third and fourth punch means whereby to anchor saidterminal loops, and means for thereafter moving said third and fourthpunch means to punch additional terminal loops from the cable whilepulling wires to form the loops from opposite ends of the cable.
 12. Theapparatus defined in claim 11 in which the means for stopping said punchmeans with the first and second punch means in alignment with theterminal loops punched by the third and fourth punch means comprises:cooperating spaced lights and a photocell for stopping movement of thepunch means after a distance corresponding to the spacing between theterminal loops formed by the respective first and third, and second andfourth punch means.
 13. The apparatus defined in claim 9 including: saidfirst and third punch means, and said second and fourth punch meansbeing mounted, respectively, on common carrier means, and said die meanscooperating with said punch means being also mounted on said commoncarrier means; and means for simultaneously moving said carrier means inopposite directions longitudinally of the cable.
 14. The apparatusdefined in claim 13 including: piston-and-cylinder operating means forsaid punch means individual thereto and also mounted on the carriermeans to be bodily movable therewith.
 15. The apparatus defined in claim9 including: supporting means for said die means extendinglongitudinally of the cable when in punch position, and movable into andout of position supporting the die means adjacent the cable for punchingoperation.
 16. The apparatus defined in claim 9 including: means foroperating supporting means for the die means in synchronism with theoperation of the punch means so that the die means is moved intosupported position to receive the punch means prior to operation of anypunch means into engagement therewith.
 17. The apparatus defined inclaim 9 including air blast means cooperating with said die means forblowing insulating particles cut from the cable from the die apparatus.18. The apparatus defined as in claim 9 including: a movable frame uponwhich said cable is mounted in supported relation; means supporting saidframe for movement into and out of cable punching position; trimmingmeans for the ends of the cable; and means for swinging said frame whilesupported in the apparatus to position the ends of the cable adjacentthe trimming means for a trimming operation removing excess insulationfrom the ends of the cable.
 19. The apparatus defined in claim 18including: means for automatically operating said trimming means aftersaid frame has swung into the position locating the ends of the cable atthe trimming means.